The Plasma cutting machine is a processing method that uses the heat of a high-temperature plasma arc to melt (and evaporate) the metal part or part of the incision of the workpiece and remove the molten metal by the momentum of high-speed plasma to form an incision. Plasma cutting machines are widely used in automobiles, locomotives, pressure vessels, chemical machinery, nuclear industry, general machinery, construction machinery, steel structures, and other industries. Efficient use of the machine can prolong the service life
Methods to Reduce Consumption of Consumables
1. Ensure correct gas pressure and flow of the plasma
The correct gas pressure and flow of the plasma are very important to the service life of the consumables. If the air pressure is too high, the life of the electrode will be greatly reduced; if the air pressure is too low, the life of the nozzle will be affected.
2. Use reasonable cutting distance
According to the requirements of the instruction manual, adopt a reasonable cutting distance. The cutting distance is the distance between the cutting nozzle and the working surface. When perforating, try to use 2 times the normal cutting distance or the maximum height that can be transmitted by the plasma arc.
3. The thickness of the perforation should be within the allowable range of the machine system
The plasma cutting machine cannot pierce the steel plate that exceeds the working thickness. The usual piercing thickness is 1/2 of the normal cutting thickness. For example, the 100A system is set to cut 1 inch (about 25mm) of carbon steel, and the piercing thickness of this system should be 0.5 inches (about 12.5mm).
4. Do not overuse nozzles
Overusing the nozzle (exceeding the operating current of the nozzle) will damage the nozzle very quickly. The current intensity should be 95% of the working current of the nozzle. For example, the amperage of a 100A nozzle should be set to 95A.
5. Keep the plasma dry and clean
Plasma systems require dry and clean plasma gas to work properly. Dirty gas is usually a problem with gas compression systems, which can shorten the life of consumables and cause abnormal damage. The method to test the gas quality is to set the cutting torch in the test state and put a mirror under it and consume the gas in the cutting torch. If there is water vapor and mist on the mirror, you need to find out the cause and correct it.
6. The cut should start from the edge
When possible, start cutting from the edge, rather than piercing and then cutting. Using the edge as a starting point will prolong the life of the consumable, the correct method is to aim the nozzle directly at the edge of the workpiece before starting the plasma arc.
7. Avoid the elongated extension of the plasma arc
If the plasma arc can only reach the work surface by stretching and expanding, the plasma arc will produce this stretching and expansion at the beginning and end of the cut, which will cause abnormal damage to the nozzle. This problem can be avoided if the correct edge start technique is used and the proper timing of the “break-off” signal is used.
8. Reduce unnecessary “starting (or piloting)” time
Both the nozzle and electrode wear out very quickly when starting the arc, and the torch should be placed within walking distance of the cutting metal before starting.
9. Apply splash chemical paint to the case
Anti-splash chemistry helps reduce slag buildup on the shield, but be sure to remove the shield from the torch before applying the splash coating.
10. Remove the slag from the protective case
Slag on the torch guard should be cleaned frequently, otherwise, this slag will cause a destructive heavy plasma arc.
11. Purge gas after replacing consumables
After replacing consumables or shutting down for a long time, the gas should be removed (2 to 3 minutes is appropriate) to ensure that the moisture and mist are discharged from the torch.
12. Keep torches and consumables as clean as possible
Any dirt on the torch and consumables can greatly affect the function of the plasma system. When replacing consumables, put them on a clean flannel, check the connection threads of the torch frequently, and clean the electrode contact surface and nozzle with a hydrogen peroxide-based cleaner.
13. Remove oxides from air or oxygen nozzles
When air or oxygen plasma is used, oxides can be deposited in the nozzle, which can affect airflow and reduce the life of consumables. Wipe the inside of the nozzle with a clean flannel to remove oxide.
14. Check airflow and cooling flow daily
One of the most common causes of torch damage is the lack of cooling flow, the airflow, and air pressure (if air-cooled) or coolant (if liquid-cooled) to the cutting torque need to be checked frequently, and stop immediately if insufficient airflow or leakage is found.
3 Tips For Maintaining Plasma Cutting Machine
1. Daily maintenance
- The dirt on the machine tool and the guide rails must be cleaned every working day to keep the bed clean. The air source and power supply must be turned off when off work and the residual air in the machine tool pipe belt must be emptied at the same time.
- If you leave the machine for a long time, turn off the power to prevent non-professional operation.
- Pay attention to observing whether there is lubricating oil on the surface of the machine’s horizontal and longitudinal guide rails and racks to keep them well lubricated!
2. Weekly maintenance
- The plasma cutting machine should be thoroughly cleaned every week, the horizontal and vertical guide rails, the transmission gear racks should be cleaned, and the lubricating oil should be filled.
- Check whether the horizontal and vertical rail wipers work normally, and replace them in time if they are not normal.
- Check whether all cutting torches are loose, clean up the garbage at the ignition gun mouth, and keep the ignition normal.
- If there is an automatic height adjustment device, check whether it is sensitive and whether to replace the probe.
3. Monthly and quarterly maintenance
- Check whether there is garbage at the main air inlet and whether all valves and pressure gauges work normally.
- Check whether all air pipe joints are loose and all pipes are not damaged. Tighten or replace as necessary.
- Check all transmission parts for looseness, check the meshing of gears and racks, and make adjustments if necessary.
- Loosen the tightening device and push the pulley by hand to see if it can come and go freely. If there is any abnormality, adjust or replace it in time.
- Check the clamping block, steel belt, and guide wheel for looseness and tightness of the steel belt, and adjust if necessary.
- Check the power cabinet and operating platform to see if the fastening screws are loose, and use a vacuum cleaner or blower to clean the dust in the cabinet.
- Check whether the wiring head is loose (refer to the electrical manual for details)
- Check the performance of all buttons and selector switches, replace damaged ones
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2 thoughts on “How to Use And Maintain Plasma Cutting Machine Efficiently”
Hi my plasma cutting machine is working for 2 years and needs some consumables
So glad to have received your response
Can you email me the consumables you need and I’ll give you a quote